Sunteți pe pagina 1din 50

Definitions

A useful glossary with 500


maintenance & reliability terms

www.LCE.com
5S A 5 step program to create, stabilize, organize and sustain
improved workplace environment. The 5 steps are: Seri (Sort) –
organization (all necessary items close at hand, unnecessary
items removed from the area); Seiton (Straighten) – orderliness
(Everything in its place); Seiso (Shine) – cleanliness (clean,
identify necessary repairs, effect repairs); Seiketsu
(Standardize)– standardized methods of organization, cleaning,
and daily activities (create standards, safe work practices,
operator check lists, etc.); Shitsuke (Sustain)– discipline
(implement inspections, audits, and action plans to ensure
sustainment).
ABC see Activity Based Costing

ABC Analysis Method of classifying materials on the basis of relative importance


i.e. Monetary value; Usage, Availability of resources; Variations in
Lead time; Material criticality for the running of a facility.

Action Plan The specific steps that must be taken to execute group decisions,
including who does what by when.

Activity Based Costing A method that allows an organization to determine the actual cost
associated with each product and service produced by the
organization based on their use of resources.

Actual Delivery Date The actual date the supplier delivers the material.

Adjustment (1) Minor tune-up action requiring hand tools, no parts and less
than one half hour. Adjustments restore parts or assembly
relationships such as tolerance, alignment, tension and tightness.
(2) Write up, write down, of inventory as a result of a cycle count to
adjust to the correct quantity.

Administrative Information Information used to administer the Maintenance Program. Typical:


Error Reports, Open Work Order Lists, etc.

Allocation Quantities of MRO materials that have been assigned to one or


more Work Orders, but have not been “issued” from the storeroom
to Maintenance or Production.

© Life Cycle Engineering 2008


Andon Board A visual control device in a production area, typically a lighted
overhead display, giving the current status of the production
system and alerting team members to problems.

Area (or Zone) Maintenance A type of maintenance in which the first-line Maintenance
Supervisor is responsible for all maintenance within a reasonable-
sized geographical area.

Area System The Area System is a form of decentralization. It is the regrouping


of forces into smaller, more manageable units. It is a philosophy
of operation that establishes responsible units capable of solving
their own problems and running their own show, within the
framework of authority conferred, while reporting the results.

Asset Lowest level of equipment that requires monitoring maintenance


cost, equipment history and reliability information, i.e. Motor, VFD,
Pump, Gearbox, Fan, Fan coil, etc.

Asset Part Pertaining to a maintenance storeroom, a part that has inventory


value.

Asset Value The book value of property owned and listed on the balance sheet.

Attitude of Error Free Work Our personal commitment to fulfill our agreement with our
customers “the first time, every time.”

Authorized User Any person who is authorized, by assignment of a password, to


enter and use the CMMS.

Automatic Storage & Retrieval A computer-controlled method for stocking, moving and selecting
System parts in a storeroom with little or no human material handling,
typically used in high volume areas where storage density is
important because of space constraints.

Autonomation Automation with human intelligence. Refers to semi-automatic


processes where the operator and machine work together.
Autonomation allows man-machine separation providing automatic
detection and line stoppage. The purpose is to free equipment
from the necessity of constant human attention, separate people
from machine and allow workers flexibility to perform multiple
operations. Also referred to as Jidoka.

© Life Cycle Engineering 2008


Backlog The total number of estimated labor hours, by craft and priority,
required to complete all identified but incomplete planned and
scheduled work. Used as an index in determining how well
maintenance is keeping up with the rate of work generation. Used
also to help establish the proper size and composition of the work
force. (See Open Work Order File.)

Backlog Purge The evaluation of backlog work orders that are duplicates, now
considered as unnecessary, orders that the work has been
completed, but not completed in the CMMS. The evaluation is
conducted with representatives of Production, Maintenance and
Work Planning. The identified work orders are then completed or
cancelled in the CMMS with comments noting the reason for
removing the work order from the backlog.

Balanced Production All operations or cells producing at the same cycle time. In a
balanced system, the cell cycle time is less than takt time.

Bar Code A machine readable symbol consisting of a series of parallel,


adjacent bars, and spaces. Predetermined width patterns are
used to represent actual data in the symbol. As the scanning
device is moved across the symbol, the width pattern of the bars
and spaces (Commonly referred to as “quiet zones”) is analyzed
by the reading equipment and the original data is recovered.

Batch-and-Queue Producing more than one piece of an item and then moving those
items forward to the next operation before they are all actually
needed there. Thus, items need to wait in a queue.

Benchmarking The process of measuring products, services, and practices


against those of leading companies.

Benefit Tracking A defined cost benefit from a work process that is tracked over a
period of time.

Best-in-Class A best-known example of performance in a particular operation.


One needs to define both the class and the operation to avoid
using the term loosely.

© Life Cycle Engineering 2008


Bill of Lading Document transferring goods from the shipper to the carrier and
from the carrier to the recipient.

Bill of Materials (1) All maintenance repairable or replaceable components for


assets, assemblies and sub-assemblies. (2) Components that
make up a Production assembly. The BOM is broken down into a
Parent (the Main Piece of Equipment or the End Product of the
manufacturing process) and its children (components that make
up the equipment or end product).

Black Belt Six Sigma team leaders responsible for implementing process
improvement projects within the business.

Blanket Purchase Order A document that identifies the product or service to be purchased,
the cost, the terms and conditions, and the estimated quantity for a
specified period of time. Material releases are used to identify the
quantity to be purchased within the specific period of time against
the base purchase order. These releases are usually repetitive in
nature and define requirements on regular intervals.

Blitz A fast and focused process for improving some component of


business _ a product line, a machine, or a process. It utilizes a
cross-functional team of employees for a quick problem-solving
exercise, where they focus on designing and implementing
solutions to meet some well-defined goals.

BOM see Bill of Materials

Bottleneck Any resource whose capacity is equal to, or less than the demand
placed on it, or which controls the maximum rate of production of
resources ahead or behind the resource in the process stream.

BPR See Business Process Reengineering

Brainstorm A basic problem-solving tool which uses the unevaluated ideas of


group members to generate a list of possible options.
Brainstorming can generate lists of (1) problems, (2) causes, (3)
solutions and (4) actions, or any list where the creativity of the
group would open up new possibilities.

© Life Cycle Engineering 2008


Breakdown Maintenance The performance of maintenance to put failed equipment back on-
line; the failure having occurred without early warning by the
Preventive Maintenance System.

Break-In Work Emergency or urgent work that breaks into scheduled work.
Urgent work may have enough lead-time to be put on the Daily
Schedule.

Budget A plan that includes an estimate of future costs and revenues


related to expected activities. The budget serves as a pattern for
and a control over future operations. MRO budget: Covers items
needed for the operation of a facility, but are not part of the
finished product. Capital Budget: Acquisition of equipment that is
capitalized as a depreciable asset on a company’s balance sheet.
Materials Budget: Covers a firm’s need for production materials
and components.

Business Cycle A seemingly recurring change in general business activity


alternating between low points and high points.

Business Plan A statement of income projections, costs, and profits usually


accompanied by budgets and a projected balance sheet as well as
a cash flow statement.

Business Process A management approach aiming at improvements by means of


Reengineering elevating efficiency and effectiveness of the processes that exist
within and across organizations. The key to BPR is for
organizations to look at their business processes from a "clean
slate" perspective and determine how they can best construct
these processes to improve how they conduct business.

Business process reengineering is also known as BPR, Business


Process Redesign, Business Transformation, or Business Process
Change Management.

Buyer Individual whose functions may include vendor selection,


negotiation, order placement, vendor follow-up, measurement and
control of vendor performance, value analysis, evaluation of new
materials and processes, etc.

Capacity Constraint Resources Non-bottleneck resources that, based on the sequence in which
they perform their jobs, can act as a constraint.

© Life Cycle Engineering 2008


Capital Assets (1) Items having a long life and requiring a relatively high dollar
outlay for acquisition. (2) Items for which the cost is more properly
chargeable to a capital account rather than to an operating
expense account. (3) In addition to land and buildings, capital
assets include other long-life depreciable items such as furniture,
fixtures, and equipment required for the manufacture and
distribution of products. Virtually all of today’s communication and
building systems are grouped in the capital asset category.

Capital Funded Work authorized by a capital fund authorization.

Carrying Costs Cost of carrying inventory usually defined as a percentage of the


dollar value of inventory per unit of time (generally one year). This
depends mainly on the cost of capital invested as well as the costs
of maintaining inventory, such as taxes and insurance,
obsolescence, spoilage, and space occupied. Such costs usually
vary from 20 to 40% annually, depending on the environment (cf.
Cost of capital, Economic Order Quantity).

Category The types of work which make up the work load performed by
Maintenance. Typical: PM, emergency, urgent and planned work.

Cells The layout of machines of different types performing different


operations in a tight sequence, typically in a U-shape, to permit
single piece flow and flexible deployment of human effort.

Certificate of Origin A document which specifies the country of origin of the goods
being shipped.

Certified Supplier A status awarded to a supplier who consistently meets


predetermined quality, cost, delivery, financial, and count
objectives. Incoming inspection may not be required.

Chaku-Chaku A method of conducting single-piece flow, where the operator


proceeds from machine to machine, taking the part from one
machine and loading it into the next.

© Life Cycle Engineering 2008


Change Agent Change agents always need the ability to get all people affected
by the project involved, to ensure their support and commitment.
This requires a high competency as the basis for acceptance as
well as soft skills, which are often summarized as emotional
intelligence (right brain activity). This includes the ability to
communicate, to understand and to take into account opinions and
doubts of others. Change projects involve a great variety of factors
and forces. These factors do not only comprise the reasons and
objectives for change, but also the existing state of the
organization, values, beliefs and behaviors of its people. Many
change projects challenge the existing cultural framework of an
organization. Efforts to change such lasting values, however, lead
to resistance and denial. More than in technology based projects
(e.g. implementation of new software), it takes the acceptance and
the support of all people affected by such projects to make them
succeed. It is the change agent’s task to generate this acceptance
in order to implement change with the people, not against them.

Changeover The reconfiguration of an asset (e.g. dies, other hardware, and/or


operating software), normally accomplished by
production/operations personnel, to produce a different product.

Chronic Problem One which is characterized by long duration or frequent


occurrence; one which we've chosen to live with and have
accepted as a standard.

CMMS See Computerized Maintenance Management System

Spare Parts List A list of recommended items and quantities that should be kept on
hand or readily available to effectively maintain an asset.
COGS See Cost of Goods Sold

Commercial Invoice A standard document indicating the value of a shipment and all
associated charges.

Commonly Used Parts A combination of standard replacement parts and hardware items
that may be used on many components and pieces of equipment.

Computer Maintenance Computerized systems that schedule, track and monitor


Management System maintenance activities and provide cost, component item, tooling,
personnel and other reporting data and history.

© Life Cycle Engineering 2008


Conditional Probability of The probability that a failure will occur in a specific time period,
Failure provided that the item concerned has survived to the beginning of
that period.

Confirming Order A purchase order issued to a supplier listing the goods or services
and terms of an order placed orally or otherwise before the usual
purchase document.

Conflict of Interest Any business activity, personal, or company related, that interferes
with a company’s goals or that entails unethical or illegal actions.

Consensus A group decision-making method resulting in all members


agreeing to go along with a certain judgment even though one or
more individuals would have handled the matter differently. The
method relies on leaders and members exploring facts, data and
opinions of the membership to ensure all relevant information is
considered and members have had a chance to speak their peace
and voice their concerns.

Consigned Stocks Inventories that are in the possession of customers, dealers,


agents, etc., but remain the property of the manufacturer by
agreement with those in possession.

Consignment (1) A shipment that is handled by a common carrier. (2) The


process of a supplier placing goods at a customer location without
receiving payment until after the goods are sold or used.

Constraint Anything that limits a system from achieving higher performance,


or throughput.

Construction The creation of a new facility or the changing of the configuration


or capacity of a building facility or utility. Although often performed
with Maintenance Department Resources, construction work is not
maintenance and should not be charged to the Maintenance
Budget, where it becomes very misleading.

Consumables Supply of materials (such as paint, cleaning materials, or fuel) that


are consumed or exhausted in the production or sale of a product
or service. Syn. Consumable tooling, supplies; expendables.

© Life Cycle Engineering 2008


Continuous Flow Production A process where items are produced and moved from one
processing step to the next one piece at a time. Each process
makes only the one piece that the next process needs, and the
transfer batch size is one. Also called "single-piece flow" or "one-
piece flow."
Contract An agreement between two or more competent persons or
companies to perform or not to perform specific acts or services or
to deliver merchandise. A contract may be oral or written. A
Purchase Order, when accepted by a supplier, becomes a
contract.

Contract Accounting The function of collecting costs incurred on a given job or contract,
usually in a progress payment situation. Certain US government
contracting procedures require contract accounting.

Control A process by which comparisons are made between the plan and
the performance, either during or after execution. Control relies on
effective, complete planning and accurate quantitative
observations. It is the process of comparing these two operations.

Coordination Daily adjustments of maintenance actions to achieve the best


short-term use of resources or to accommodate changes in
operational needs. The act of synchronizing various functions and
duties to obtain a desired result. It is easy to see that, if methods
and efforts are not synchronized, people act at cross purposes
with each other and desired goals cannot be reached.

Corrective Action Solving problems; identifying and resolving problems

Corrective Maintenance Maintenance required restoring an item to a satisfactory condition,


usually identified by PM activity. It can be emergency, urgent or
planned work.

Cost The value of money that has been used up to produce something
and hence is not available for use anymore.

Cost Center The smallest segment of an organization for which costs are
collected and formally reported, typically a department. The
criteria in defining cost centers are that the cost be significant and
that the area of responsibility be clearly defined. A cost center is
not necessarily identical to a work center; normally a cost center
encompasses more than one work center, but this may not always
be the case.

© Life Cycle Engineering 2008


Cost Control The application of procedures to monitor expenditures and
performance against progress of projects and manufacturing
operations with projected completion, to measure variances from
authorized budgets and allow effective action to be taken to
achieve minimal costs.

Cost History A historical picture of cost expenditures against a specific unit of


equipment.

Cost of Capital The cost of maintaining a dollar of capital invested for a certain
period, normally one year. This cost is normally expressed as a
percentage and may be based on factors such as the average
expected return on alternative investments and current bank
interest rate for borrowing.

Cost of Goods Sold An accounting classification useful for determining the amount of
direct materials, direct labor, and allocated overhead associated
with the products sold during a given period of time.

Cost of Poor Quality The cost associated with providing poor-quality products or
services. There are four categories of costs: 1) Internal Failure
Costs – Costs associated with defects found before the customer
receives the product or service. 2) External Failure Costs—Costs
associated with defects found after the customer receives the
product or service. 3) Appraisal costs—Costs incurred to
determine the degree of conformance to quality requirements. 4)
Prevention Costs—Costs incurred to keep failure and appraisal
costs to a minimum.

Cost of Quality The measure of what it costs when we do our job right or when we
do it wrong. It measures the cost of error as well as prevention
and detection costs.

Cost, Insurance, and Freight Used along with a destination point, the cost of insurance and
delivery of cargo incurred by the seller to that destination. Beyond
the CIF point, the buyer is responsible for all costs, including
import duties and fees, customs clearance, etc.

Covariance The impact of one variable upon others in the same group.

© Life Cycle Engineering 2008


CPM see Critical Path Method

Criteria Standards on which judgments can be based. Teams use criteria


to evaluate options.

Critical Asset Assets identified as critical by reliability engineering that, when


unable to perform, cause severe consequences for the plant or
facility and lead to a shutdown of production.

Critical Spares Key parts and/or components of an asset that need to be in stock
or readily available because of the potential production, service
and/or financial implications of an equipment failure requiring
these materials.
Critical Path Method A mathematically based algorithm for scheduling a set of project
activities. It is an important tool for effective project management.

Current State Map A Business Process Reengineering technique that helps visualize
the current state of a process and identifies sources of waste.

Customer The individual who receives the immediate output of your efforts
(normally a co-worker or boss). The “customer” is the person with
whom requirements are set and agreed upon.

Cycle Counting A physical inventory-taking technique where inventory is counted


on a periodic schedule rather than once a year.

Daily Schedule Jobs that the maintenance supervisors have selected for
technician’s assignment the following day. These jobs normally
come from the Weekly Forecast. Urgent work that breaks into the
normal work for the week may be added as break-in work.

Deferred Maintenance Maintenance that can be postponed to some future date without
further deterioration of equipment.

Delivery Receipt Document signed by the recipient indicating receipt of the material
in good order and without damage. A bill of lading signed by the
recipient often is used as a delivery receipt. Sometimes referred
to as "Proof of Delivery".

© Life Cycle Engineering 2008


Delphi Method A quantitative Forecasting Technique where the opinions of
experts are combined in a series of iterations. The result of each
iteration is used to develop the next, so that convergence of the
experts’ opinions is obtained.

Demand Flow The concept of pulling raw materials and products through the
process strictly according to the rate customers demand the
product.

Dependent Events Events that occur only after a previous event has been completed.

Desired Performance The level of performance acceptable to the owner or user of a


physical asset or system.

Distribution Requirements The function of determining the need to replenish inventory at


Planning branch warehouses. A time-phased order point approach is used
where the planned orders at the branch warehouse are “exploded”
via MRP logic to become gross requirements on the supplying
source.
Downtime Time when the machines in the plant are not producing because
they are broken or down for repairs or other reasons (idle time).

DRP see Distribution Requirements Planning

Due Date The date at which purchased material or production on order is


due to be available for use.

Duties Taxes levied by governments on the importation, exportation, or


use of goods.

EAM See Enterprise Asset Management

Economic Order Quantity A fixed order quantity that minimizes the sum of carrying costs and
administrative purchasing costs.

Acknowledged Delivery Date The date that a supplier promises to deliver material to the
customer's dock.

ADD Acknowledged Delivery Date

© Life Cycle Engineering 2008


Emergency Repairs Immediate repairs needed as a result of failure or stoppage of
critical equipment during a scheduled operating period. Imminent
danger to personnel and extensive further equipment damage as
well as substantial production loss will result if equipment is not
repaired immediately. Scheduled work must be interrupted and
overtime, if needed, would be authorized in order to perform
emergency repairs. Emergency repairs should be completed
within one day after discovery.

Emergency Spares Replacement equipment kept in reserve in anticipation of outages.

EMP see Equipment Maintenance Plan

Empowerment To invest with power or give authority to complete.

Engineering Change A revision to a Parts List, Bill of Materials, or Drawings, authorized


by the engineering department. Changes are usually identified by
a control number and are made for safety, cost reduction, or
functionality reasons. In order to effectively implement
engineering changes, all affected functions, such as materials,
quality assurance, engineering, maintenance, tool room personnel,
etc., should review and agree to the changes.

Engineering Work Order A control document for initiating engineering project work. Often
this is an authorization to use the maintenance work force or a
contractor in support of specific engineering project work.

Enterprise Asset Management Information system that integrates all asset-related applications for
an entire enterprise. Incorporates at least maintenance
management, financial / budgeting, materials management, and
reliability functionality.

Enterprise Resource Planning Information system that integrates all related applications for an
entire enterprise. Industry term for the broad set of activities,
supported by multi-module application software to help manage
the business, including (1) Product Planning; (2) Parts Purchasing;
(3) Maintaining inventories; (4) Interacting with suppliers; (5)
Providing customer service: and (6) Tracking orders.

© Life Cycle Engineering 2008


Environmental Consequences The result of a failure mode and/or multiple failures that could
have environmental consequences if it could breach any
corporate, municipal, regional, national, district, or international
environmental standard or regulation, which applies to the physical
asset or system under consideration.

Equipment Audit Inspection of mechanical and electrical components of equipment


to detect out-of-specifications conditions in order to assess the
adequacy of shop PM and general maintenance practices.

Equipment Maintenance Plan A plan for maintaining equipment based on asset criticality and
best life cycle costs.

Equipment Modification The major changing of an existing unit of equipment or a facility


from original design specification. This is not maintenance.

Equipment Repair History The chronological listing of significant repair actions performed on
key units of equipment so that chronic, persistent problems can be
identified and corrected. Historic repair actions also help guide
current repairs. Used as the basis for developing a forecast. (See
Forecasting.)
ERP See Enterprise Resource Planning

Error Proofing Designing a potential failure or cause of failure out of a product or


process.

ETR see Equipment Trouble Report

Evident Failure A failure mode that will on its own become evident to the opening
crew under normal circumstances.

Expediting The “rushing” or “chasing” of production or purchase orders that


are needed in less than normal lead time.

Expense Financial Burden or outlay; Cost

Expense Part Pertaining to a maintenance storeroom, parts that have been


expensed and have no inventory valuation.

© Life Cycle Engineering 2008


Expensed Maintenance work that does not meet the criteria for capitalization
and is charged against the maintenance budget or non-
maintenance work charged to the operating budget.

External Setup Setup procedures that can be performed while equipment is in


motion.

Failure Analysis The act of determining the physical failure mechanism resulting in
the functional failure of a component or equipment.

Failure Coding Classification of equipment failure events for the purpose of data
analysis and trending. Normally, four types of failure codes
available for use in many CMMS are: Part, Damage, Cause, and
Activity.

Failure Consequences The way(s) in which a failure mode or a multiple failure matters.

Failure Effect Occurs when a failure mode happens

Failure Evaluation Mode A procedure in which each potential failure mode in every sub-item
Analysis of an item is analyzed to determine its effect on other sub-items
and on the required function of each item.

Failure Finding Task Scheduled task that determines when a specific hidden failure has
occurred.

Failure Management Policy Statement of purpose that does include on-condition tasks,
scheduled restoration, scheduled discard, failure finding, run to
failure, and redesign.

Failure Mode One event causing a functional failure

FAS See Free Along Side

FEMA See Failure Evaluation Mode Analysis

FIFO See First-In/First Out

First-In/First Out Method of inventory valuation for accounting purposes. The


assumption is that the oldest inventory (first in) is the first to be
used (first out), but there is no necessary relationship with the
actual physical movement of specific items.

© Life Cycle Engineering 2008


Five Why’s The 5 why’s typically refers to the practice of asking, five times,
why the failure has occurred in order to get to the root
cause/causes of the problem. There can be more than one cause
to a problem as well. Failure to determine the root cause assures
that you will be treating the symptoms of the problem instead of its
cause, in which case, you will continue to have the same problems
over and over again.

Fixed Location Storage A method of storage in which a relatively permanent location is


assigned for the storage of each item in a storeroom or
warehouse. Although more space is needed to store parts than in
a random location storage system, fixed locations become familiar,
and therefore a locator file may not be necessary.

Floor Stocks, Bench Stock Stocks of inexpensive production parts held in the factory from
which production workers can draw without requisitions.

Flow A main objective of the lean production effort, and one of the
important concepts that passed directly from Henry Ford to
Toyota. Ford recognized that, ideally, production should flow
continuously all the way from raw material to the customer and
envisioned realizing that ideal through a production system that
acted as one long conveyor.

FOB Destination Shipping terms in which the seller bears risk until the goods are
transported to the buyer’s dock, after which risk will pass to the
buyer.

FOB origin Shipping terms in which the seller bears risk until it loads the
goods onto an appropriate carrier, after which the buyer assumes
the risk of loss and must submit a claim against the carrier for
damage or loss in-transit.

Forecasting The long term projection of the best time to carry out major
maintenance actions. Repair history provides a major source of
these projections.

Free Issues Commonly used parts and maintenance supplies kept in


Maintenance Shop, nearby in high maintenance areas or outside
the storeroom. Withdrawal of this stock requires no requisition or
other paperwork.

Free Along Side Shipping terms that require the Seller to place the goods on a
loading dock accessible to the carrier, at which the risk of loss
transfers to the buyer.

© Life Cycle Engineering 2008


Function That which the owner or user of a physical asset or system wants
it to do.

Function Failure The state in which a physical asset or system is unable to perform
a specific function to a level of performance that is acceptable to
its owner or user.

Functional Work Work that does not lend itself to the area-type supervision, either
because it requires specialized skills or because the nature of the
work requires maximum mobility. Functional work is performed
generally on a plant-wide basis rather than by area. Examples of
functional work are: electrical and instrument repairs, trash
pickup, road repairs, lawn mowing and plant beautification, etc.

Functional Layout The practice of grouping machines or activities by type of


operation performed.

Functional Maintenance A type of maintenance in which the first-line maintenance


supervisor is responsible for conducting a specific kind of
maintenance, e.g., pump maintenance for the entire plant.

Future State Map A blueprint for lean implementation. Your organization_s vision,
which forms the basis of your implementation plan by helping to
design how the process should operate. Typically achieved by
identifying and then eliminating forms of waste in the product or
process.

Gemba A Japanese word, where the real action take place. Gemba is
where the activities to satisfy the customer are carried out.

Goal The end towards which effort is directed. Goals are the steps
directed towards the obtainment of an objective; as such, goals
are more specific than objectives.

Hardware Items Bolts, nuts, washers, cotter pins and other items that are low in
unit costs, carried in ample quantity, are readily available from
suppliers and should be stocked in ample supply by users.

Heijunka A method of leveling total manufacturing volume as constant as


possible. This involves averaging both the volume and sequence
of different model types on a mixed-model production line. Also
referred to as Production Smoothing.

© Life Cycle Engineering 2008


Hidden Failure Failure occurring that is not detectable by or evident to the
operating crew.

Hidden Function Function that is not detectable by or evident to the operating crew.

Hoshin Kanri A process of setting goals and measurement of progress from top
management. It is designed to ensure that the entire organization
is engaged with the Lean process.

Hoshin Planning Also known as Management by Policy or Strategy Deployment. A


means by which goals are established and measures are created
to ensure progress toward those goals. HP keeps activities at all
levels of the company aligned with its overarching strategic plans.
HP typically begins with the "visioning process" which addresses
the key questions: Where do you want to be in the future? How do
want to get there? When do you want to achieve your goal? And
who will be involved in achieving the goals? HP then
systematically explodes the whats, whos and hows throughout the
entire organization.

HP See Hoshin Planning

IED Inner Exchange of Dies (See Internal Setup)

Impact The effect in dollars of a problem. High impact problems are


addressed first. Measured by analysis of “cost of quality.”

Impact Analysis The tool associated with the principle of “Measure by the Cost of
Quality.” This tool puts into quantifiable and no-quantifiable terms,
the effects that arise from a problem that we are currently living
with. A person or group would use this tool to get management's
attention, prioritize problems or justify the cost of a solution.

Import declaration Declares to US Customs the content and value of the shipment, in
government terminology.

Inactive Inventory Designates the stocks that are in excess of contemplated


consumption within the planning period.

Indirect Charges Labor hours distributed to indirect accounting codes for non-work
activities such as safety meetings, union meetings, lunch, major
delays, etc.

© Life Cycle Engineering 2008


Indirect Charges Man-hours distributed to indirect accounting codes for non-work
activities such as safety meetings, union meetings, lunch, major
delays, etc.

Indirect Cost Cost that is not directly incurred by a particular job or operation.

Indirect Labor Work required to support production in general without being


related to a specific product.

Initial Capability Level of performance in which a physical asset or system is


capable at the moment it enters service.

Inspection The checking of equipment with the primary purpose of


determining equipment reliability or repair needs and their relative
urgency, often accompanied by cleaning, adjusting and minor
component replacement.
Installation The installation of new or rebuilt equipment or relocation of fixed
equipment.

Insurance Parts Parts used in critical equipment and equipment components. Their
usage is unpredictable since the mean times between failures of
the times where they are used is unpredictable. Their costs range
from a few cents to millions of dollars. Normally, they are carried in
inventory under tightest control. Not having these “insurance parts”
in stock can result in extended downtime and major losses of
production.

Insurance spare components A component of an insurance spare that can cause extensive
downtime when not in inventory.

Insurance spares Materials, when not in stock, can cause downtime of equipment
and loss of production, beyond specified limits, that may lead to
severe disruption or plant shutdown.

Internal Setup Setup procedures that must be performed while machine is


stopped.

Inventory Items in a physical stocking location or in-process involved in the


manufacture and/or distribution of a product. Inventory may
consist of finished goods ready for sale; production work-in-
process; raw materials; or storeroom items.
Inventory Investment The total value of all levels of inventory.

© Life Cycle Engineering 2008


Inventory turnover The number of times that an inventory cycles during the year. It is
the ratio of annualized cost of sales or material usage to inventory
investment at a particular time or an average.

Inventory write-off A financial adjustment made because inventory is no longer


saleable or because of shrinkage, i.e. the value of the physical
inventory is less than its book value.

ISO9000 Series Standards A set of five individual but related international standards on
quality management and quality assurance developed to help
companies effectively document the quality system elements to be
implemented to maintain an efficient quality system. The
standards, initially published in 1987, are not specific to any
particular industry, product, or service. The standards were
developed by the International Standards Organization (ISO), a
specialized international agency for standardization composed of
the national standards bodies of 91 countries.

Item Master File Computer record containing identifying and descriptive data,
ordering parameters, inventory status and other information.

Jidoka Stopping a line automatically when a defective part is detected.


See Autonomation.

JIT see Just-In-Time

Just-in-Time JIT is a system for producing and delivering the right items at the
right time, in the right amounts. The key elements of Just-in-Time
are Flow, Pull, Standard Work, and Takt Time. Implementing JIT
requires most features of lean manufacturing.

Kaikaku Radical improvement, usually applied only once within a value


stream, used as a precursor to kaizen activities.

Kaizen (Kai = change; Zen = good) Continuous, incremental


improvement of an activity to create more value with less waste.
The term Kaizen Blitz refers to a team approach to quickly tear
down and rebuild a process layout to function more efficiently.
Continuing improvement in personal life, home life, social life, and
working life. When applied to the workplace, kaizen means
continuing improvement involving everyone – managers and
workers alike. Every process can and should be continually
evaluated and improved in terms of time required, resources used,
resultant quality, and other aspects relevant to the process.

© Life Cycle Engineering 2008


Kaizen Event Any action whose output is intended to be an improvement to an
existing process. In the US this is sometimes misconstrued to be
a method of implementing change. The true intent of a kaizen
event is to hold small events attended by the owners and
operators of a process to make improvements to that process
which are within scope of the process participants.

Kanban A signaling device that gives instruction for production,


conveyance, and/or replenishment of items in a pull system.

Key Performance Indicator Historical data that provides current status and trend information
regarding the effectiveness of work processes, e.g.
productivity/operating costs, maintenance labor and material
costs, and performance/availability data.

Kitting The process of pulling material from stock, combining with other
items required to complete a production or maintenance order,
and preparing them for delivery to a secured production or
maintenance area.
KPI see Key Performance Indicator

Labor Utilization The percentage of time that a maintenance crew is available to


perform productive work during a scheduled working period.

Last In, First Out Method of inventory valuation for accounting purposes. The
assumption is made that the most recently received (Last In) is the
last to be used or sold (Last Out). There is no necessary
relationship with the actual physical movement of specific items.

Lay-Up Maintenance Preventive Maintenance, usually non-intrusive, that is designed to


ensure that key inventory items such as electric motors,
gearboxes, bearings, belts, gaskets, pillow blocks, etc. are ready
for use when issued. Lay up maintenance activities are often
affected via a Preventive Maintenance Work Order.

LCCA see Life Cycle Cost Analysis

Lead Time The total time a customer must wait to receive a product after
placing an order. When a scheduling and production system is
running at or below capacity, lead time and throughput time are
the same. When demand exceeds the capacity of a system, there
is additional waiting time before the start of scheduling and
production, and lead time exceeds throughput time.

© Life Cycle Engineering 2008


Lean Business processes requiring less human effort, capital
investment, floor space, materials, and time in all aspects of
operation. The philosophy of continually reducing waste in all
areas and in all forms. Characteristics of a Lean process include:
1) Production is pulled through the process only when it is needed
at the next step instead of a push system 2) Smooth flow instead
of batches 3) Zero inventory 4) Standardized processes 5) Waste
reduction 6) Lead time reduction 7) Employee involvement

Life Cycle Cost Analysis The act of analyzing the total costs associated with the ownership
of an asset. See Life Cycle Cost.

Life Cycle Cost Also known as the the total cost of ownership which includes the
costs associated with the acquisition, installation, useage,
anticipated downtime, planned maintenance, and the disposal (if
any) of the capital asset.

LIFO see Last In, First Out

Line Balancing Equalizing cycle times for relatively small units of the
manufacturing process, through proper assignment of workers and
machines; ensures smooth production flow.

Load-Load See Chaku-Chaku

Locator System A system for maintaining a record of the storage locations of items
in inventory.

Lubrication Route A dedicated path taken by a lubrication technician for periodic


lubrication of equipment. A route should have a check sheet of all
the equipment that describes the type of lubricant, number of lube
points, type of fittings, when and how lubrication should be done
and the oil change frequency.

Maintenance The routine, recurring repair and upkeep required to keep facilities
and equipment in a safe effective condition enabling it to be
utilized at original design capacity and efficiency or some other
level specified by management as the maintenance objective.
Maintenance is normally an operating cost, although some
projects, such as overhauls, performed with maintenance
resources may be capitalized. The term maintenance means
capacity assurance, to minimize downtime, increase production,
and maximize profits.

© Life Cycle Engineering 2008


Maintenance Engineering A staff effort aimed at ensuring that maintenance techniques are
effective, that equipment is engineered for maximum
maintainability, that persistent and chronic problems are
discovered and corrective actions or modifications made.
Responsible for review or the adequacy of repair materials used in
maintenance; determination of critical parts and adequacy of
stocking levels of replacement parts; monitoring the utilization of
the maintenance work force; preparation of specifications for
repair and new equipment selection, and other related similar
actions.

Maintenance Material(s) The parts and supplies used to maintain and repair plant
equipment and facilities.

Maintenance, Repair, and Maintenance materials purchased or in stores that are used for
Operating Supplies repair of or used in operating assets or facilities.

Maintenance Repair Operations Fixing any sort of mechanical or electrical device should it become
out of order or broken (repair) as well as performing the routine
actions which keep the device in working order (maintenance) or
prevent trouble from arising (preventive maintenance).

Maintenance Supplies Commonly used support items that aid in maintaining and
repairing plant equipment and facilities.

Maintenance Work The repair and upkeep of existing equipment, facilities, buildings
or areas in accordance with current design specifications to keep
them in a safe, effective condition while meeting their intended
purposes.
Maintenance Work Order A formal document for controlling planned and scheduled work.

Maintenance Work Order A means of communicating maintenance needs, planning,


System scheduling, controlling work and focusing field data to create
information.
Maintenance Work Request An informal document for requesting unscheduled or emergency
work or a format for requesting all maintenance work. In the latter
usage, once the MWR is approved, it becomes a MWO.

Major Repairs Extensive, non-routine, scheduled repairs, requiring deliberate


shutdown of equipment, the use of repair crew possibly covering
several elapsed shifts, significant materials, rigging and, if needed,
the use of lifting equipment.

© Life Cycle Engineering 2008


Make or Buy Decision The act of deciding whether to produce an item in-house or buy it
from an outside vendor.

Manage by Prevention Planning job activities in order to keep problems from occurring.
Doing so provides the biggest return for the amount of resources
expended.
Manifest A document that consolidates the details of the contents from
multiple shipments for one or more recipients.

Material Requisition An authorization that identifies the type and quantity of parts
required to be withdrawn from an inventory.

Maximum Order Quantity An order quantity modifier, applied after the lot size has been
calculated, that limits the order quantity to a pre-established
maximum.
MCA see Motor Current Analysis

Mean Time Between Failure An indicator of the overall reliability of an item. The mean time
between failures of a repairable item that repaired and returned to
use.
Mean Time To Failure An indicator of the overall reliability of an item. The mean time
between failures of a non-repairable item.

Mean Time To Repair An indicator of the overall maintainability of an item (includes


impact of design, accessibility, and efficiency of the craftsperson
affecting the repair). The mean time taken to repair failures of a
repairable item.
Measurable Capable of being compared to a standard.

Min/Max system An inventory management technique in which a replenishment


order is placed when the available stock falls to the minimum level
(reorder point) or below it. The order quantity is the difference
between the available inventory and the maximum (target) level.

Minor Repairs Repairs usually performed by one man using hand tools, few parts
and usually completed in less than one-half shift.

© Life Cycle Engineering 2008


Mistake Proofing Any change to an operation that helps the operator reduce or
eliminate mistakes.

Mixed Model Production Capability to produce a variety of models, that in fact differ in labor
and material content, on the same production line; allows for
efficient utilization of resources while providing rapid response to
marketplace demands.

Motor Current Analysis A predictive technology which analyzes variations in the input
current to a motor (using methods much like vibration analysis)
that can be used to identify most motor and cable faults including:
winding problems, rotor problems, connection problems, insulation
failure.
MRO see Maintenance Repair Operations

MRO Supplies see Maintenance, Repair and Operating Supplies

MTBF see Mean Time Between Failure

MTTF see Mean Tim To Failure

MTTR see Mean Time To Repair

Muda Waste; anything that interrupts the flow of products and services
through the value stream and out to the customer is designated
Muda _or waste.

Multiple Failure Event occurring if a protected function fails while its protective
device or protective system is in a failed state.

MWO see Maintenance Work Order

MWR see Maintenance Work Request

NASIC Abbreviation for North American Standard Industrial Classification.


These are codes that are used to categorize companies into
industry groupings.

Natural Work Group A group of individuals from within a given department or function
who develop and implement solutions to problems occurring within
the jurisdiction of that department or function.

© Life Cycle Engineering 2008


NDT see Non-Destructive Testing

Non-Destructive Testing Techniques intended to predict wear rate, state of deterioration or


imminent equipment failure. Techniques include dye penetrant
testing, magnetic particle inspection, ultrasonic thickness testing,
and the like. May also include other predictive technologies such
as vibration analysis, oil sampling, airborne ultrasonic’s,
thermography, etc.

Non-Maintenance Construction, major modification of equipment, installation or


relocation of equipment where none previously existed. This work
is normally capital-funded. Some non-maintenance work of a
minor nature could be expensed.

Non-Operational Consequence Failure mode, with non operational consequences, that is not
hidden, and does not have safety, environmental or operational
consequences.
Non-Routine Maintenance Maintenance performed at irregular intervals with each job unique.

Non-Value Added Activities or actions taken that add no real value to the product or
service making such activities or action a form of waste.

NWG see Natural Work Group

Objective Something towards which effort is directed; an aim, goal or end of


action. A strategic position to be attained or a purpose to be
achieved. Objectives are statements of general plans towards
which an organization's efforts are directed.

Obsolescence A state where materials are no longer usable due to a model or


style change, technological development, deterioration, asset
removal, inactivity, etc.

OED Outer Exchange of Dies (See External Setup)

OEE see Overall Equipment Effectiveness

OGA see Oil & Gas Analysis

© Life Cycle Engineering 2008


Oil & Gas Analysis A predictive maintenance technique performed on transformer oil
which can detect breakdown of the oil, contamination, insulation
degradation and, arcing - to name a few.

Oil Analysis A predictive maintenance technique used to determine the quality


of the lubricant and/or the condition of the equipment being
lubricated.

On Hand Balance shown in perpetual inventory records as being physically


present at the stocking location.

On-Condition Task A scheduled task that is used to determine whether a potential


failure has occurred.

One Piece Flow Producing one unit at a time, as opposed to producing in large lots
or batches.

Open Ended Questions Questions that require a response and solicit information such as
who, what, where when, why, or how.

Open Work Order File A listing of all work orders currently open.

Operating Context Circumstances in which a physical asset or system is expected to


operate.

Operating Expenses Production-related expenses incurred in conversion of raw


materials into finished product (examples: power/fuels consumed
in the process; consumable materials/parts such as additives,
alloys, expendable tools/equipment; transportation of WIP through
the manufacturing process; production labor).

Operating Maintenance Specific maintenance activities accomplished by


production/operations personnel in direct support of Changeover
activities (Examples: Cleaning; adjustment; lubrication;
replacement of parts, asset setup, test asset operation prior to
product run), or repair/replacement of production-related parts
(knives, blades, belts) normally worn and requiring replacement
during normal operations.

© Life Cycle Engineering 2008


Operational Consequence Failure mode or multiple failures that has operational
consequences if it could adversely affect the operational capability
of a physical asset or system (output, product quality, customer
service, military capability, or operating costs in addition to the
cost of repair).

Operator Care Specific, detailed activities accomplished by operators to ensure


proper asset operation, routinely check asset operating
parameters (pressure, temperature, speed, etc), make necessary
adjustments, lubricate, and make minor repairs incidental to the
production process, and provide early detection of potential
problems requiring maintenance support.

Opportunity Cost The return on capital that could have resulted had the capital been
used for some purpose other than its present use. It usually refers
to the best alternative use of the capital; at other times, however,
to the average return from feasible alternatives.

Optimization Achieving the best possible solution to a problem in terms of a


specified objective function.

Output The information, service or products supplied to customers.

Overall Equipment OEE is a metric used to monitor the effective use of equipment. It
Effectiveness is obtained from the product of three ratios: 1. Availability ratio –
Time for which equipment was available for operation. 2.
Performance ratio – Rate of production divided by capacity of
machine to produce. 3. Quality ratio – Quantity of ‘right the first
time’ production divided by total production (‘right the first time’ +
setoff + scrap).

Overhauls The inspection, teardown and repair of a total unit of equipment to


restore it to effective operating condition in accordance with
current design specifications.

Overproduction Producing more, sooner or faster than is required by the next


process.

Packing List List of the contents of each carton in a shipment.

© Life Cycle Engineering 2008


Pareto Analysis A problem-solving tool that helps arrange collected data so that
comparisons can be made about problem causes. “Pareto's
Principle” states that results and causes of results are not equally
distributed, but that 80% of the results come from 20% of the
causes. Therefore, teams can focus their efforts on
eliminating/reducing the 20% of the causes that will produce
results. The “Pareto Chart” displays the data.

Part Number A number that serves to uniquely identify a component, product, or


raw material.

Partial Order Any shipment received or shipped that is less than the amount
ordered.

Past Due An order that has not been completed or delivered on time.

P-Card Procurement (credit) Cards, typically provided for low-value


procurement of parts or materials when normal procurement
channels are not available (nights, weekends, etc.).

PDCA (Plan, Do, Check, Act) PLAN Senior management should use the visioning process in the
context of its Business Plan. HP translates the Business Plans to
action plans, meaningful to all levels of the organization. DO
Answer the whats, hows, and whos for the total number of tiers for
your organization; remember, the fewer the number of tiers, the
better. Also, this is the time to bring management together and
provide them with a basic understanding of HP mechanics.
CHECK On a periodic basis, review the measurements and note
what you’ve learned that can help in the future. ACT Make the
necessary adjustments to plans and priorities in order to ensure
the success of the strategy breakthroughs.

PdM see Predictive Maintenance

PDPC see Process Decision Program Chart

Perfection Always optimizing value-added activities and eliminating waste.

Performance Indices Ratios, graphs, etc., which convey, at a glance, short-term


accomplishments versus long-term trends.

© Life Cycle Engineering 2008


Periodic Maintenance Cyclical maintenance actions or component replacements carried
out at known regular intervals. Usually intrusive, they are often
based on repair history and regulated by current PM inspection
results; includes inspecting, testing, partial dismantling, replacing
consumables or complete equipment items, lubricating, cleaning
and other work short of overhaul or renovation. This PM usually
requires equipment to be scheduled out of service and may be
done at intermediate intervals, usually ranging from monthly to
annually.

Perpetual Inventory Inventory record-keeping system where each transaction is


recorded and a new balance computed.

Personal Protective Equipment Individual safety equipment.

PERT see Program Evaluation and Review Technique

PF Curve see Potential to Failure Curve

PF Interval see Potential to Failure Interval

Physical Inventory Determination of inventory quantity by an actual count.

Pick List Document used to pick materials for work orders.

Planned/Scheduled Work which, by virtue of cost, importance, extensive labor and


Maintenance Work materials required, etc., should be planned to ensure, when
scheduled, that it can be completed with the least interruption to
operations and the most efficient use of maintenance resources.

Planning Determination of resources needed and the development of


anticipated actions necessary to perform a scheduled major job.
An orderly appraisal and guarantee of all the prerequisites
necessary to ensure completion of a given job at a predetermined
time. It covers availability of ordered equipment, stores, materials,
production, shutdowns, sketches, prints, specifications, etc.

PM see Preventive Maintenance

PM Check Sheets A document that lists tasks to be performed on a designated unit.


It defines with instructions what component is to be inspected,
what to look for, what limits are acceptable and a means to report
the conditions found. It also notes any minor adjustments if limits
are exceeded and repairs are not necessary. Minor materials and
parts are identified for possible periodic change out (filter, etc..).It
also notes limits that, if exceeded, require corrective maintenance.
© Life Cycle Engineering 2008
parts are identified for possible periodic change out (filter, etc..).It
also notes limits that, if exceeded, require corrective maintenance.

Poka-Yoke A manufacturing technique of preventing mistakes by designing


the manufacturing process, equipment, and tools so that an
operation literally cannot be performed incorrectly; an attempt to
perform incorrectly, as well as being prevented, is usually met with
a warning signal of some sort.

Policy A definite course or method of action selected from among


alternatives and in light of given conditions to aid managers to
guide and determine present and future decisions about recurring
situations or functions. Policies are broad direction of an
authoritative nature laid down for the purpose of enabling all
management decisions to be properly determined and adequately
carried out in the successful attainment of the goals established.

Potential to Failure Curve Comparative charting of different approaches to maintenance and


the incidence of failure.

Potential to Failure interval Interval between the point at which a potential failure becomes
detectable and the point at which it degrades into a functional
failure. (Also known as ‘failure development period’ or ‘lead time
to failure.’)
PPE see Personal Protective Equipment

Predictive Maintenance The use of instruments and analysis to determine equipment


condition in order to predict failure before it takes place so
corrective maintenance can be done in a planned and scheduled
fashion. Examples include vibration analysis, oil analysis,
thermography, airborne ultrasonic’s, NDT, motor current signature
analysis, trending of process parameters, etc.

Prevention Analysis The tool associated with the principle of “Manage by Prevention.”
By using this tool, problems can be brought out and dealt with
before an activity is performed. Planning before the fact is always
less expensive than reacting and patching after the fact.

© Life Cycle Engineering 2008


Preventive Maintenance Time or cycle based actions performed to prevent system
functional failure. This proactive maintenance type generally
includes scheduled restoration and scheduled discard tasks.

Preventive Maintenance Includes major work involving dismantling and inspecting


Overhaul and Shutdown equipment before breakdown occurs. It includes replacing or
reconditioning equipment and components that have reached or
are approaching their theoretical maximum life limit as determined
by time or predictive techniques.

Primary Function(s) The function(s) constituting reasons why a physical asset or


system is acquired by its owner or user.

Priority The relative importance of a single job in relationship to other jobs,


operational needs, safety, equipment condition, etc., and the time-
frame within which the job should be done. Used primarily for
Planned Work which subsequently will be scheduled.

Priority Worksheet A problem-solving tool used to help in decision making; similar to


Triadic Evaluation except that options are rated against several
criteria.

Problem/Cause A serious condition or situation which prevents us from doing our


job right the first time. The problem/cause is the difference
between our current output and our desired output. It could be
chronic or sporadic.
Problem/Cause Statements Identified effects, clearly understood by the group and stated in
terms that reflect the impact of the problem/cause.

Procedure A series of steps followed in a regular definite order in which


activities or tasks are to be carried out.

Process The flow of material in time and space. The accumulation of sub-
processes or operations that transform material from raw material
to finished product.

Process Decision Program A technique designed to help prepare contingency plans. The
Chart emphasis of the PDPC is to identify the consequential impact of
failure on activity plans, and create appropriate contingency plans
to limit risks. Process diagrams and planning tree diagrams are
extended by a couple of levels when the PDPC is applied to the
bottom level tasks on those diagrams.

© Life Cycle Engineering 2008


Process Kaizen Improvements made at an individual process or in a specific area.
Sometimes called "point kaizen".

Processing Time The time a product is actually being worked on in a machine or


work area.

Program Evaluation and Review A network planning technique for the analysis of a project’s
technique completion time. It uses an algorithm that permits identification of
the critical path, the string of sequential activities that determines
the project’s completion time. PERT time estimates are
probabilistic, based on pessimistic, most likely, and optimistic time
estimates for each activity.

Project Work Construction, installation, relocation or modification of equipment,


buildings, facilities or utilities to gain economic advantage, replace
worn, damaged or obsolete equipment, satisfy a safety
requirement, attain additional operating capacity or meet a basic
need. Usually capital-funded, seldom true maintenance.

Protective Device or Protective Device or system intended to avoid, eliminate, or minimize


System consequences of failure in another system.

Pull System One of the 3 elements of JIT. In the pull systems, the downstream
process takes the product they need and pulls it from the
producer. This customers pull is a signal to the producer that the
product is sold. The pull system links accurate information with the
process to minimize waiting and overproduction.

Purchase Order The authorizing document used to formalize a transaction with a


vendor.

Push System In contrast to the pull system, product is pushed into a process,
regardless of whether it is needed. The pushed product goes into
inventory, and lacking a pull signal from the customer indicating
that it has been bought, more of the same product could be
overproduced and put in inventory.

QFD see Quality Function Deployment

© Life Cycle Engineering 2008


Quality Meeting the measurable requirements agreed upon with the
customer.
Quality Function Deployment A visual decision-making procedure for multi-skilled project teams
which develops a common understanding of the voice of the
customer and a consensus on the final engineering specifications
of the product that has the commitment of the entire team. QFD
integrates the perspectives of team members from different
disciplines, ensures that their efforts are focused on resolving key
trade-offs in a consistent manner against measurable performance
targets for the product, and deploys these decisions through
successive levels of detail. The use of QFD eliminates expensive
backflows and rework as projects near launch.

Queue Time The time a product spends in a line awaiting the next design, order
processing, or fabrication step.

Quick Changeover The ability to change tooling and fixtures rapidly (usually minutes),
so multiple products can be run on the same machine. See also
SMED

Random Location Storage A storage technique in which parts are placed in any space that is
empty when they arrive at the storeroom. Although this random
method requires the use of a locator file to identify part locations, it
often requires less storage space than a fixed location storage
method.
Ranking Index for Maintenance A method for prioritizing maintenance work that takes both
Expenditures equipment criticality and work importance into account to arrive at
an overall job priority.

Ranking Index Maintenance A method for prioritizing maintenance work that takes both
Expenditures equipment criticality and work importance into account to arrive at
an overall job priority.

RASI A matrix to show Responsibility, Accountability, Support and


Information for each step of a work flow process.

RAV see Replacement Asset Value

Raw Materials Purchased items or extracted materials that are converted via the
manufacturing process into components and products.

RCM see Reliability Centered Maintenance

© Life Cycle Engineering 2008


RE see Reliability Engineering

Rebuild The repair of a component to restore it to serviceable condition in


accordance with current design specifications.

Reengineering The engine that drives Time-Based Competition. To gain speed,


firms must apply the principles of reengineering to rethink and
redesign every process and move it closer to the customer.

Regulations Rules that are concerned with methods of activity or performance.


Both rules and regulations are derived from the broader policies of
the organization.

Reliability The probability that an item can perform its intended function for a
specified interval under stated conditions. (MIL-STD-721C)

Reliability Centered A process used to determine the maintenance requirements of


Maintenance physical assets in their present operating context.

Reliability Engineering That set of design, development and manufacturing tasks by


which reliability is achieved. See RELIABILITY. The main
objectives of this strategic minded staff function performing
reliability engineering are: (1) To apply engineering knowledge and
specialist techniques to prevent or reduce the likelihood or
frequency of failures. (2) To identify and correct the causes of
failures that do occur. (3) To manage identified risk by
determining the best ways of coping with (mitigating) the effects of
failure if and when they do occur. (4) To apply methods for
estimating the likely reliability of assets and for analyzing reliability
data.
Relocate Move fixed equipment to a different stationary location.

Repair Restoration of equipment to a condition equivalent to its original or


designed capacity and efficiency by replacement of parts or after
deterioration, overhaul to enable continued operation.

Repair History The chronological listing of significant repairs made on key units of
equipment and the analysis of these repairs to help identify
chronic, repetitive problems, failure trends and the life-span of
critical components.

© Life Cycle Engineering 2008


Repetitive Maintenance Maintenance jobs that have a known labor and material content
and occur regularly (daily, weekly, etc.)

Replacement Asset Value Total value of all installed assets at a facility or plant.

Replacement Materials Standard Materials that can be used on more than one component or piece
of equipment.

Replacement The process of removing badly worn parts (chains, belts, bearings,
seals, gaskets, etc. that are no longer capable of being adjusted.
Scheduled replacement is performed to avoid costly repairs.

Reposition Movement of mobile equipment to a new working location.

Request for Proposal An invitation for suppliers, often through a bidding process, to
submit a proposal on a specific commodity or service. A bidding
process is one of the best methods for leveraging a company's
negotiating ability and purchasing power with suppliers. The
Request process brings structure to the procurement decision and
allows the risks and benefits to be identified clearly upfront. The
Request purchase process is lengthier than others, so it is used
only where its many advantages outweigh any disadvantages and
delays caused. The added benefit of input from a broad spectrum
of functional experts ensures that the solution chosen will suit the
company's requirements.

Requested Maintenance A request for maintenance service that did not emanate from the
PM system, but did provide sufficient lead-time to allow proper,
proactive, planning and scheduling.

Required Delivery Date Date required for the material to be delivered.

Requirement Documented and agreed upon standards and objectives that


specify what is to be done, how it is done and what is expected as
the output of the efforts.

Requirements Analysis The tool associated with the principle “Meeting the Requirements.”
A basic tool used to analyze supplier/customer relationships to
make sure clear requirements have been communicated.

© Life Cycle Engineering 2008


Requisition A request for material or service.

Resource Utilization Using a resource in a way that increases throughput.

Return Material Authorization A document, often with a serial or control number, provided by a
vendor that authorizes return of the vendor's material from the
customer location back to the vendor's location due to damage,
over shipment, incorrect material, etc.

Return On Investment Typically used as a way to determine worthiness of project or


major investment. (Overall benefit / savings divided by total cost).

RFP see Request for Proposal

Right Size Matching tooling and equipment to the job and space
requirements of lean production.

RIME see Ranking Index for Maintenance Expenditures

RMA see Return Material Authorization

ROI see Return On Investment

Root Cause Analysis Root cause analysis (RCA) is a process which systematically uses
any one or combination of a class of problem solving methods
aimed at identifying the root causes of problems or events. The
stewardship of this process is usually a function of Reliability
Engineering.
Routine Maintenance Services performed consistently in the same manner, including
such things as grass-cutting, freeze-protection, janitorial services,
etc.

Rules Standards or guides for performing specific operations or limiting


the activities of people.

Run to Failure A failure management policy permitting a specific failure mode to


occur without any attempt to anticipate or prevent it.

Safety Consequences A failure mode or multiple failure that could potentially result in
injuring or killing a human being.

© Life Cycle Engineering 2008


Schedule Compliance The percentage to which the weekly schedule “contract” was
adhered to, calculated as the percentage of scheduled labor hours
completed against total scheduled labor hours (%).

Scheduled Discard Task that entails discarding an item or component at or before a


specified age limit regardless of its condition at the time.

Scheduled Maintenance Extensive major repair, rebuilds, overhauls, major component


change-outs, etc., requiring advanced planning, lead time to
assemble materials, scheduling equipment shutdown to ensure
availability of repair-facility space and allocation labor.

Scheduled Restoration Task(s) restoring the initial capability of an item or component at or


before a specified age limit, regardless of its condition at the time.

Scheduled Shutdown The scheduled removal of a facility from service to open, clean,
inspect, repair, add, alter, close and test operating components;
then return of the facility to service with a predetermined interval of
time.

Scheduling Determination of the best time to perform a planned maintenance


job to appreciate operational needs and the best use of
maintenance resources. A system of accomplishing engineering
and maintenance at a predetermined time that coincides as
closely as possible with the date on which the work is required. It
implies the orderly use of engineering and craft skills to
accomplish the greatest good at any particular time.

Scrap Material outside of specifications and/or possessing characteristics


that make retention or rework impractical. Unusable parts.

Secondary Function Functions which a physical asset or system has to fulfill apart from
its primary functions, such as those needed to fulfill regulatory
requirements and those which concern issues such as protection,
control, containment, comfort, appearance, structural integrity, and
energy efficiency.

Sensei A master or teacher who assists a student in learning how to


implement improved or better practices.

© Life Cycle Engineering 2008


Sequential Changeover Also sequential set-up. When changeover times are within Takt
time, changeovers can be performed one after another in a flow
line. Sequential changeover assures that the lost time for each
process in the line is minimized to one Takt beat. A set-up team or
expert follows the operator, so that by the time the operator has
made one round of the flow line (at Takt time), it has been
completely changed over to the next product.

Serviceability Design characteristic that allows the easy and efficient


performance of service activities. Service activities include those
activities required to keep equipment in operating condition, such
as lubrication, fueling, oiling, and cleaning. A measure of the
degree to which servicing of an item will be accomplished within a
given time under specified conditions.

Seven Wastes Taiichi Ohno_s original catalog of the wastes commonly found in
physical production.
(1) overproduction ahead of demand
(2) waiting for the next processing stop, unnecessary
(3) transportation of materials or information
(4) processing of parts due to poor tool or product design or
misunderstood customer requirements
(5) inventories more than the absolute minimum
(6) unnecessary motion by employees during the course of their
work
(7) defects

SFMEA see Simplified Failure Modes and Effects Analysis

Shelf Life The amount of time an item may be held in inventory before it
becomes questionable as a usable item.

Shelf Life Control/Rotation A technique of physical first-in, first-out (FIFO) usage aimed at
minimizing stock obsolescence.

Shutdown The removal of a facility from service to open, clean, inspect,


repair, add, alter, close and test operating components; then
return of the facility to service with a predetermined interval of
time.
Simplified Failure Modes and A focused approach to identify likely failures and the potential for
Effects Analysis collateral damages.

© Life Cycle Engineering 2008


Single Minute Exchange of Dies A series of techniques designed for changeovers of production
machinery in less than ten minutes. Obviously, the long-term
objective is always Zero Setup, in which changeovers are
instantaneous and do not interfere in any way with continuous
flow. Also referred to as Quick Changeover.

Single-Piece Flow A situation in which products proceed, one complete product at a


time, through various operations in design, order taking, and
production, without interruptions, backflows, or scrap.

Single-Source Supplier A company that is selected to have 100% of the business for a
part, even though alternate suppliers may be available.

Six Sigma Six Sigma is a process improvement strategy, originally developed


by Motorola, that's designed to remove the causes of defects and
errors in manufacturing and business processes using a statistical
methodology called DMAIC (Design, Measure, Analyze, Improve,
Control). Six sigma creates a special infrastructure of people
within the organization ("Black Belts") who are experts in the
facilitation of the DMAIC process.

SKU See Stock keeping Unit

SMED see Single Minute Exchange of Dies

Solution An activity that eliminates (or reduces the impact of) a root cause.

SOP See Standard Operating Procedure.

Specialized Spare Parts Parts that are used in and are unique to specific equipment
components and equipment.

Specifications Technical definition of configuration or performance requirements


to meet intended utilization of equipment or materials.

Sporadic Problem A problem that is characterized by only occasional occurrence or


by scattered instances; also a problem that triggers alarm signals
and requires a response.

© Life Cycle Engineering 2008


Staging The process of putting kitted material in a secured holding area for
pick up at a later time.

Standard Operating Procedure A written procedure used to ensure reasonable uniformity each
time a significant task is performed.

Standard Replacement Parts Parts that can be used on more than one component or piece of
equipment. These parts may be carried in stock by suppliers for a
number of users. Delivery lead times are predictable so stock outs
can be managed.

Standard Work A precise description of each work activity specifying cycle time,
takt time, the work sequence of specific tasks, and the minimum
inventory of parts on hand needed to conduct the activity.

Standards An established norm or requirement. It is usually a formal


document that establishes uniform engineering or technical
criteria, methods, processes and practices.

Standing Work Order A type of work order that is used to capture labor used on routine,
repetitive actions where capture of history is not important.
Examples include shop cleanup, toolbox meetings, etc.

Step Definition A definition of each step of the workflow process.

Stock keeping Unit An item in stores with an assigned inventory number.

Stock out A situation where material is showing available in the system, but
is not physically available when it is needed.

Stock Out Costs The costs associated with a stock out. Those costs may include
lost sales, backorder costs, expediting, and additional
manufacturing and purchasing costs.

Stock Point A designated location in an active area of operation into which


material is placed and from which it is taken. Not necessarily a
stockroom isolated from activity, it is a way of tracking and
controlling active material.

© Life Cycle Engineering 2008


Stock Status A periodic report showing the inventory on hand and usually
showing the inventory on order and some sales or usage history
for the products that are covered in the stock status report.

Storage The retention of parts or products for future use or shipment.

Storage Costs A subset of inventory carrying costs, including the cost of


warehouse utilities, material handling personnel, equipment
maintenance, building maintenance, and security personnel.

Stores Stored materials used for maintaining facilities, assets, operating


supplies, and production materials. Room in which stored
components, parts, assemblies, tools, fixtures, etc. are kept.

Stores Issue Order See Pick List

Sub-Contracting Sending production or maintenance work outside to another


manufacturer.

Sub-Assembly Logical group of assets that serves a common function within an


assembly, i.e. Pump drive train, Fan drive train, Chilled water
within AHU, steam system with AHU etc. A component assembly
that are part of a larger assembly.

Sub-Optimization A condition where gains made in one activity are offset by losses
in another activity or activities, created by the same actions
creating gains in the first activity.

Substitution The use of a non-primary product or component, normally when


the primary item is not available.

Sunk Cost The un-recovered balance of an investment. It is a cost, already


paid, that is not relevant to the decision, concerning the future that
is being made. Capital already invested that for some reason
cannot be retrieved. A past cost that has no relevance with
respect to future receipts and disbursements of a facility
undergoing an economic study. This concept implies that since a
past outlay is the same regardless of the alternative selected, it
should not influence the choice between alternatives.
Symptom Evidence that a problem/cause exists. This evidence needs to be
clarified to determine the impact of the problem/cause.

© Life Cycle Engineering 2008


System An orderly, habitual or routine method, or methods, by which the
regular activities of a part of a business, like maintenance, are
carried on. Within Maintenance, System usually refers to the
Maintenance Management Information System.

System Kaizen Improvement aimed at an entire value stream.

Takt Time The available production time divided by the rate of customer
demand. For example, if customers demand 240 widgets per day
and the factory operates 480 minutes per day, takt time is two
minutes; if customers want two new products designed per month,
takt time is two weeks. Takt time sets the pace of production to
match the rate of customer demand and becomes the heartbeat of
any lean system.

Tank Inventory Goods stored in tanks. These goods may be raw materials,
intermediates, or finished goods. The description of inventory as
tank inventory indicates the necessity of calculating the quantity on
hand from the levels within the tanks.

Tare-weight The weight of a substance, obtained by deducting the weight of


the empty container from the gross weight of the full container.

Target A specific, quantitative measurement established in order to


measure progress towards a goal.

Target Costing Designing a product to meet a specific objective. Target costing


involves setting the planned selling price, subtracting the desired
profit as well as marketing and distribution costs, leaving the
required manufacturing or target cost.

Target Inventory Level In a min-max inventory system, the equivalent of the maximum.
The target inventory is equal to the order point plus a variable
order quantity. It is often called an order-up-to inventory level and
is used in a periodic review system.

Teardown time The time needed to remove a setup from a machine or facility.
Teardown is an element of manufacturing lead-time, but it is often
allowed for in a setup or runtime rather than separately.

© Life Cycle Engineering 2008


Technically Feasible Task(s) physically possible to reduce, or enable action to be taken
to reduce the consequences of the associated failure mode to an
extent that might be acceptable to the owner or user of the asset.

Theory of Constraints A lean management philosophy that stresses removal of


constraints or bottlenecks to increase throughput while decreasing
inventory and operating expenses.

Thermography A predictive maintenance technique that measures infrared energy


emanating from an object. Usually used to detect high resistance
in electrical connections or excessive friction in operating
equipment.
Throughput Time The time required for a product to proceed from concept to launch,
order to delivery, or raw materials into the hands of the customer.
This includes both processing and queue time.

Time and Material Contracts Provides payment for labor and overhead at a given rate per hour,
plus the sales price of parts, supplies, and materials.

Time Distribution Card The authorized document for reporting the use of labor against
specific jobs.

Tolerance Allowable departure from a nominal value established by design


engineers that is deemed acceptable for the functioning of the
product or service over its life cycle.

Tolerance Limits The upper and lower extreme values permitted by the tolerance.
In work measurement, the limits between which a specified
operation times value or other work unit will be expected to vary.

Tool Calibration Frequency The recommended length of time between tool calibrations. It is
normally expressed in days.

Tool Number The identification number assigned to reference and controls a


specific tool.

Total Cost Sum of all costs, regardless of which department or firm incurs
them.

© Life Cycle Engineering 2008


Total Productive Maintenance An innovative approach to maintenance that optimizes equipment
effectiveness eliminates breakdowns and promotes autonomous
operator maintenance through day-to-day activities involving the
total work force.

Total Quality Management A business management strategy aimed at embedding awareness


of quality in all organizational processes. TQM has been widely
used in manufacturing, education, call centers, government, and
service industries, as well as NASA space and science programs.

TPM see Total Productive Maintenance

TQM see Total Quality Management

Two Bin System A type of fixed order system in which inventory is carried in two
bins. A replenishment quantity is ordered when the first bin is
empty. During the replenishment lead-time, material is used from
the second bin. When the material is received, the second bin is
refilled and the excess put into the working bin. At this time stock
is drawn from the first bin until it is again exhausted. This term is
also used loosely to describe any fixed order system even when
physical bins do not exist.

UE see Ultrasound

Ultrasound Predictive technique used to detect conditions hidden by housings,


covers or other obstructions.

Universal Product Code A barcode symbology (i.e., a specific type of barcode), that is
widely used in the United States and Canada for tracking trade
items in stores.
Unscheduled Repairs Unscheduled non-emergency work that could result in becoming
an emergency/breakdown if not addressed. Work must be
completed in the current schedule week with little danger of
equipment failure in the interim. A decision between production
supervision and maintenance as to what work will be interrupted in
the current week's schedule to allow this work to take place.
Schedule compliance will decrease as a result.
UPC see Universal Product Code

Valuation The technique of determining worth, typically of inventory.

© Life Cycle Engineering 2008


Value A capability provided to a customer, for which they will pay, at the
right time at an appropriate price, as defined in each case by the
customer.
Value Chain Activities outside of your organization that add value to your final
product, such as the value adding activities of your suppliers.

Value Stream The specific activities required to design, order and provide a
specific product, from concept to launch, order to delivery, and raw
materials into the hands of the customer.

Value Stream Mapping A visual representation of how product or materials flow from
supplier through manufacturing to the customer. It creates a visual
map and allows the analysis of how the process really works
(which is updated through the use of a future-state value stream).

Value-Added Analysis An activity where a process improvement team strips the process
down to it essential elements. The team isolates the activities that
in the eyes of the customer actually add value to the product or
service. The remaining non-value adding activities ("waste") are
targeted for extinction.

Vendor Managed Inventory An arrangement where an outside vendor manages their


customer's inventory by counting, restocking, and invoicing parts,
and performing other services normally done by the customer.

Verbal Orders A means of assigning emergency work when required reaction


time does not permit advanced preparation of a work order
document. Verbal orders must be followed up with a written work
order.
Vibration Analysis This Predictive Maintenance technique is widely used to evaluate
mechanical rotating equipment to determine if any undesirable
changes are present that might give an early indication of
imminent failure. Uses transducers to translate a vibration
amplitude and frequency into electronic signals to determine the
equipment's actual condition. This may lead to the
recommendation of a logical course of maintenance actions to
correct the problem before secondary damage or catastrophic
failure can occur. Additionally Vibration Analysis can be used for
the modeling, prediction, measurement and analysis of structural
dynamic response in design and root cause failure analysis. In
design, vibration modeling and prediction is used to anticipate and
avoid undesirable dynamic response. In root cause failure
analysis it is used both to understand undesirable response and
as a factor in determining true root cause.

© Life Cycle Engineering 2008


as a factor in determining true root cause.

Visual Control Monitoring systems in which deviations from desired levels are
instantly and visibly obvious. Used in a workplace organization
where everything has a place and is in its place.

Wall-to-Wall Inventory An inventory management system in which material enters a plant


and is processed through the plant into finished product without
ever having entered a formal stock area.

Warehouse Management A key part of the supply chain and primarily aims to control the
System movement and storage of materials within a warehouse and
process the associated transactions, including shipping, receiving,
put away and picking. The systems also direct and optimize stock
put away based on real-time information about the status of bin
utilization.

Warranty A commitment either expressed or implied that a certain fact


regarding the subject matter of a contract is presently true or will
be true. The word should be distinguished from guarantee, which
means a contract or promise by an entity to answer for the
performance of a product or person.

Waste Anything that uses resources, but does not add real value to the
product or service, which the customer will not pay for.

Weekly Forecast List of planned work selected from the backlog, forecasted to be
scheduled during the following week.

What if Analysis The process of evaluating alternate strategies by answering the


consequences of changes to forecasts, manufacturing plans,
inventory levels, etc.

WIP see Work in Progress

Withdrawal Removal of material from stores.

© Life Cycle Engineering 2008


Work Cell A logical and productive grouping of machinery, tooling, and
personnel which produces a family of similar products.

Work Force The personnel who carry out the work of operating and
maintaining a facility.

Work in Progress Product or inventory in various stages of completion throughout


the plant, from raw material to completed product.

Work Order An order to the machine shop for tool manufacture or to the
maintenance department for equipment maintenance or repair.
Authorization to start work on maintenance.

Work Sampling The statistical measure of the utilization of labor to determine


productivity.

Work Type The types of work that make up the workload performed by
Maintenance. Typical: PM, emergency, urgent and planned work.

Workload The number of labor hours required to carry out a maintenance


program.

World Class The philosophy of being the best, the fastest, and the lowest cost
producer of a product or service. It implies the constant
improvement of offerings to remain an industry leader and provide
the best choice for customers.

World Class Quality A term used to indicate a standard of excellence: The best of the
best.

Worth Doing Something that reduces (avoids, eliminates, or minimizes) the


consequences of the associated failure mode to an extent that
justifies the direct and indirect costs of doing the task.

WR see Maintenance Work Request

Yield Produced product related to scheduled product –OR– percentage


of a process or product that is free from defects.

© Life Cycle Engineering 2008


Life Cycle Engineering

Our mission is to enable people and organizations to achieve their full potential.
For more than 30 years, Life Cycle Engineering has provided engineering solutions that deliver lasting results for private industry, public entities,
government organizations and the military. Founded in 1976, LCE is headquartered in Charleston, South Carolina, with offices across North America.

As a professional services organization our mission is focused on our clients’ people and organizations. It is our company’s cornerstone belief that we
will not lead the industry in assisting our clients unless we excel at helping our own people and teams reach their full potential.

As a privately held firm, our business vision is shaped by this mission and influences both our short and long-term planning and decision-making. In
every aspect of our business our actions always drive people and organizations to achieve their long-term performance capability (not solely their
short-term profit or cost-cutting targets.)

Since 1976, LCE has grown to include the following solutions & services:

Reliability Consulting & Services Net-Centric Solutions Engineering & Technical Services

Reliability and maintenance solutions for Net-Centric solutions that combine Shipboard engineering and technical
industrial and government markets that Service-Oriented Architecture (SOA) support services for U.S. and foreign
help public and private enterprises gain engineering, network engineering, navies, providing expertise in electrical
improved financial performance through information assurance, test and evaluation and mechanical engineering, systems
greater capacity, lower total cost, improved services, documentation support and engineering and software development.
quality and an engaged workforce. configuration management.

ILS Services Program Support Services Education

Acquisition, logistics planning and life A full spectrum of program management The Life Cycle Institute is a life-long
cycle support services for military ships capabilities, from financial management learning resource for people engaged in
and shipboard support systems, shipboard and project plan development to planning optimizing asset reliability and performance.
combat systems and aviation systems. and estimating for industrial projects.

All LCE groups embrace our people-focused model of building strengths and employee engagement so that we can deliver successful and
sustainable solutions for our clients. Visit www.LCE.com to learn more.

To learn more about Life Cycle Engineering, contact: 843.744.7110 | info@LCE.com | www.LCE.com

S-ar putea să vă placă și